Tobacco composite cigarette tube

ABSTRACT

A cigarette blank comprising a tube having a first end and a second end, wherein the tube is made of reconstituted leaf sheet, and a filter disposed in the second end of the tube.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional application61/940,365, filed Feb. 14, 2014, the disclosure of which is incorporatedby reference in its entirety.

FIELD OF INVENTION

This invention relates generally to a cigarette blank made ofreconstituted tobacco paper. The invention also relates to methods ofmaking cigarettes from tubes made of reconstituted tobacco paper.

BACKGROUND OF THE INVENTION

Cigarette blanks are empty cigarette tubes that a user typically fillswith tobacco to make a cigarette. Cigarette blanks typically have afilter, a paper tube, and a tipping paper surrounding the filter. Thepaper used to make cigarettes is typically a wood based paper. Presentedhere is a cigarette blank made with a filter, reconstituted tobaccosheet, and tipping paper.

SUMMARY OF THE INVENTION

This invention relates to a cigarette blank comprising a tube having afirst end and a second end, wherein the tube is made of reconstitutedleaf sheet, and a filter disposed in the second end of the tube.

This invention also relates to a method of making a cigarette comprisingproviding a cigarette blank having a tube with a first end and a secondend, a filter disposed in the second end of the tube, wherein the tubeis made of reconstituted leaf sheet, providing a filling tube having afirst end, a second end, an inside diameter, and an outside diameter,providing a pin sized to fit within said filling tube, said pin having afirst end and a second end, said second end comprising a guide head,inserting said pin into said filling tube so at least a portion of theguide head of said pin extends beyond the second end of said fillingtube, dispensing the cigarette blank over said guide head and onto saidfilling tube, and retracting said pin from said filling tube.

This invention further relates to a method of making a cigarettecomprising the steps of delivering an amount of tobacco to a tobaccocompaction area, compacting the tobacco, inserting a cigarette blankmade of reconstituted leaf sheet over a filling tube, and injecting aplug of compacted tobacco into a filling tube with an injection pinaffixed to a slideable pin carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cigarette making machine of theinvention.

FIG. 2 is a side view of the tobacco conveying device of FIG. 1.

FIG. 3A is a perspective view of a portion of the cigarette makingmachine of FIG. 1.

FIG. 3B is an enlarged perspective view of a force multiplying linkageof the invention in the fully extended position.

FIG. 3C is a top view of the force multiplying linkage of FIG. 3Blocated against a center stop.

FIG. 3D is a side view of the force multiplying linkage of FIG. 3B.

FIG. 3E is a top view of the force multiplying linkage of FIG. 3B with aforce input member retracting.

FIG. 3F is a top view of the force multiplying linkage of FIG. 3B in aretracted position.

FIG. 4 is a partial perspective view of the cigarette making machine ofFIG. 1.

FIG. 5 is a perspective view of a pin mechanism of the invention.

FIG. 6A is a perspective view of a filling tube.

FIG. 6B is a side view of another filling tube.

FIG. 7A is a perspective view of a guide head and pin.

FIG. 7B is a side view of another embodiment of the guide head and pin.

FIG. 8A is a section view of a filling tube holding drum.

FIG. 8B is a section view of a filling tube mounted in a drum partiallyreceiving a guide head.

FIG. 8C is a section view of a filling tube mounted in a drum fullyreceiving a guide head.

FIG. 8D is a section view of a filling tube mounted in a drum fullyreceiving a guide head showing further a blank cigarette tube beingloaded onto the filling tube.

FIG. 8E is a section view of a filling tube mounted in a drum fullyreceiving a guide head showing further a blank cigarette tube havingbeen fully loaded on the filling tube.

FIG. 8F is a section view of an injection pin injecting a tobacco pluginto a filling tube having a blank cigarette tube loaded onto it.

FIG. 8G is a section view of a completed cigarette being ejected from afilling tube.

FIG. 9 is another partial perspective view of the cigarette makingmachine of FIG. 1.

FIG. 10 is another partial perspective view of the cigarette makingmachine of FIG. 1.

FIG. 11 is another perspective view of a pin mechanism.

FIG. 12 is another partial perspective view of a cigarette makingmachine of the invention.

FIG. 13A is a section view of a collapsible force input member of theinvention.

FIG. 13B is a top view of a collapsible force input member connected toan arm and to a force multiplying linkage.

FIG. 14 is a section view of a pin connector of the invention.

FIG. 15A is a perspective view of a linkage support locking device ofthe invention.

FIG. 15B is a detailed view of a U-shaped pivoting locking portionshowing a roller resting against the backside of a linkage support.

FIG. 15C is a detailed view of one embodiment of a distal end of thefirst leg of the U-shaped pivoting locking portion.

FIG. 15D is a detailed view of another embodiment of a distal end of thefirst leg of the U-shaped pivoting locking portion.

FIG. 15E is a side view of the linkage support locking device of FIG.15A.

FIG. 15F is a top view of the linkage support locking device of FIG. 15Ashowing a roller offset from the backside of the linkage support.

FIG. 16A is a perspective view of a spring-retained linkage supportsystem of the invention with the linkage in the center position.

FIG. 16B is a top view of the spring-retained linkage support system ofFIG. 16A with a force input member and a linkage in the retractedposition.

FIG. 16C is a top view of the spring-retained linkage support system ofFIG. 16A with a force input member in the fully extended position.

FIG. 16D is a top view of the spring-retained linkage support system ofFIG. 16A with a linkage in the center position on the return stroke of aforce input member.

FIG. 17 is a perspective view of a reduced diameter shaft injection pinof the invention.

FIG. 18 is a perspective view of a cigarette blank made fromreconstituted tobacco sheet.

FIG. 19 is an end view of the cigarette blank made from reconstitutedtobacco sheet of FIG. 18.

FIG. 20 shows the process of making a cigarette blank from reconstitutedtobacco sheet.

FIG. 21 shows a further process of making a cigarette blank fromreconstituted tobacco sheet.

FIG. 22 shows a further process of making a cigarette blank fromreconstituted tobacco sheet.

DETAILED DESCRIPTION OF THE INVENTION

A cigarette making machine 10 is illustrated in FIG. 1. The machine 10includes a base 12, a tobacco compaction mechanism 100, a tobaccoconveying device 200, a force multiplying linkage 300, a filling tubeholder 400, a pin mechanism 600, and a blank cigarette tube loader 700.

FIG. 2 illustrates the tobacco conveying device 200. The device 200generally has an input end 201, a receiving hopper 215, a tobaccoconveying zone 218, a first conveyor 202 having a top end 203 and alower end 204, and a second conveyor 205 having a top end 206 and alower end 207. The conveyors 202 and 205 are mounted between a firstside plate 217 and a second side plate (not shown). Conveyor 202 has aconveyor belt 208, and conveyor 205 has a conveyor belt 209. Theconveyor belts 208 and 209 may have styrations or fingers on them,allowing the moving belts to grip the cut tobacco. The top end 203 ofthe first conveyor 202 and the top end 206 of the second conveyor 205communicate with the receiving hopper 215. Typically, the conveyors 202and 205 converge on each other as they move in the direction of arrows211 and 212, respectively. At least one electric motor 220 may be usedto drive a gear 222 that drives the first conveyor 203 and the secondconveyor 205 (see FIGS. 1, 2).

FIG. 4 shows the tobacco compaction mechanism 100 disposed on a base 12.The tobacco compaction mechanism has a force transmitting member 304,which here is a slideable compacting plate 102, with a compacting end104 and a linkage end 106. The compacting end 104 may also have acompacting die 105. Opposite the slideable compacting plate is a secondcompacting plate, also referred to as a corresponding compacting plate108, having a compacting end 110. The corresponding compacting plate maybe slideable or it may be fixed. When the slideable compacting plate 102is retracted as shown in FIG. 4, the compacting end 104 of the slideablecompacting plate 102, the compacting end 110 of the correspondingcompacting plate 108, and a plate 112 together form a tobacco compactionarea 114. When the slideable compacting plate is moved in the directionof arrow 197 to its most distal position, the compacting end 104 of theslideable compacting plate 102 mates with the compacting end 110 of thecorresponding compacting plate 108 to form a compacted tobacco cavity118.

In operation, downwardly moving inner sides 213 and 214 of conveyors 202and 205, respectively, partially compress cut tobacco and deliver it tothe tobacco compaction area 114 (see FIG. 2). The conveyors 202 and 205run for a period of time to deliver an amount of cut tobacco into thecompaction area 114, and then stop. The amount of tobacco that isdelivered into the compaction area 114 may be within a predeterminedrange, with the exact amount being established by the operator of themachine depending on individual preferences, which may include, amongother things, the operator's preferred “draw” of the cigarette. Then, aforce input member 340 drives the force multiplying linkage 300, whichpushes the slideable compacting plate 102 toward the correspondingcompacting plate 108, further compacting the tobacco in the compactionarea 114 (see FIG. 3A). As the slideable compacting plate 102 movestoward the corresponding compacting plate 108, a top edge 107 of theslideable compacting plate 102 meets a cutting edge 264 of a knife 263(see FIG. 2). FIG. 2. The cut tobacco in the compaction area 114 is thensheared from the cut tobacco in the tobacco conveying zone 218, therebyforming a tobacco plug 265 in the compacted tobacco cavity 118.Typically, the tobacco plug 265 is smaller in diameter than an insidediameter of a filling tube and a blank cigarette tube to allow forinsertion of the tobacco plug into the filling tube and the blankcigarette tube. In one embodiment, a blank cigarette tube is a papercigarette tube and filter without tobacco.

The plate 112 may also be slideable to allow it to slide away from thecompaction area 114, thereby opening the bottom of the compaction area.With a slideable plate 112 open, excess tobacco located in the tobaccoconveying zone 218 after a number of cigarettes have been made may bedischarged through the compaction area 114 and into an excess tobaccoreceiving hopper (not shown) located below the compaction area 114. Arod 122 connects the plate 112 to a solenoid 120, which may be used toslide the plate (see FIGS. 1, 3A). Other mechanisms other than asolenoid, such as an electrical linear actuator, a pneumatic cylinder,or a wheel with an offset arm that drives a link, may also be used toslide the plate 112.

As shown in FIG. 3A, the tobacco compaction mechanism 100 has a forcemultiplying linkage 300 that pushes the slideable compacting plate 102and is pivotably attached to a supporting frame 302 by way of a firstlinkage support 322 and linkage connector 322. The force multiplyinglinkage has a first end 305, a second end 307, a first force outputmember 308 that has a first end 310 and a second end 312, and a secondforce output member 314 that has a first end 316 and a second end 318.The first force output member 308 and the second force output member 314may each have a corresponding force output member 330 and 332,respectively, to form a double link mechanism. The supporting frame 302has a first end 301 and a second end 303. The first end 310 of the firstforce output member 308 is pivotably connected to the first end 301 ofthe supporting frame 302 by way of a linkage support 320. One method ofconnecting the first end 310 of the first force output member 308 to thesupporting frame 302 and the linkage support 320 is with a first linkageconnector 322 having a linkage end 323 and an acting end 325 (see FIG.3B). Here the first linkage connector 322 is a connecting rod. A pin 324passes through an eye in the linkage end 323 of the first linkageconnector 322 and a hole in the first end 310 of the first force outputmember 308 to pivotably connect the first linkage connector to the firstforce output member. The acting end 325 of the first linkage connector322 is connected to the linkage support 320.

The second end 318 of the second force output member 314 is pivotablyconnected to a slideable compacting plate 102. One method of connectingthe second end 318 of the second force output member 314 to theslideable compacting plate 102 is with a second linkage connector 338having a linkage end 339 and an acting end 345. Here the second linkageconnector is a connecting rod. A pin 334 passes through an eye in thesecond linkage connector 338 and a hole in the second end 318 of thesecond force output member 314 to pivotably connect the second linkageconnector to the second force output member. The acting end 345 of thesecond linkage connector 338 is connected to the slideable compactingplate 102.

As shown in FIGS. 1, 3A, a first end 341 of the force input member 340,the second end 312 of the first force output member 308, and the firstend 316 of the second force output member 314 are pivotably connected byway of a pin 342 passing through an eye in the force input member 340, ahole in the second end of the first force output member, and a hole inthe first end of the second force output member. A second end 343 of theforce input member 340 is connected to an arm, described later. A centerstop 350 limits the travel of the force input member in the directionshown by arrow 352. The center stop may be adjustable by way of a bolt354 and nuts 356 and 358 that secure the center stop to a center stopvertical support 360. The stop may also include a pad 362 for cushioningthe first force output member and the second force output member as theycontact the center stop.

The force multiplying linkage 300 shown in FIG. 3A is in the retractedposition. As the force input member 340 moves in the direction of arrow352, the first end 310 of the first force output member 308 pivots aboutthe pin 324, and the second end 318 of the second force output member314 moves in the direction of arrow 197. The second end 318 of thesecond force output member 314 moving in the direction of arrow 197 alsomoves the slideable compacting plate 102 in the same direction,compacting any tobacco in the compaction area 114. When the pins 324,342, and 334 become axially aligned, the force multiplying linkage is inits fully extended position. Thereafter, continued movement of the forceinput member 340 in the direction of arrow 352 will cause the pin 342 togo over center, the second end 318 of the second force output member 314to retract slightly, and the force multiplying linkage 300 to contactthe center stop 350.

On the return stroke, the force input member 340 moves in the directionof arrow 351, pulling the force multiplying linkage 300 away from thecenter stop 350. The second end 318 of the second force output member314 and the slideable plate 102 will move in the direction of arrow 197until the pin 342 comes to center and becomes axially aligned with thepins 324 and 334. Continued movement of the force input member 340 inthe direction of arrow 351 will cause the second end 318 of the secondforce output member 314 to move toward the first end 310 of the firstforce output member 308 in the direction of arrow 198, therebyretracting the slideable compacting plate 102.

Typically, an injection pin (described later) passes through thecompacted tobacco cavity 118 when it pushes a tobacco plug 265 out ofthe compacted tobacco cavity 118 and into a filing tube. If theinjection pin is in the compacted tobacco cavity when the force inputmember 340 starts its return stroke, then the injection pin can becomepinched between the slideable compacting plate 102 and the correspondingcompacting plate 108. Methods available to prevent pinching theinjection pin include modifying the size of the injecting pin andpreventing the slideable plate from moving in the direction of arrow 197when the force input member 340 is retracting and moving the forcemultiplying linkage 300 from its over-center position against the centerstop 350 to the fully extended position when the pins 324, 342, and 334are axially aligned.

FIG. 17 depicts a reduced diameter shaft injection pin 50 having anacting end 52, a connecting end 54, and a central section 56 disposedtherebetween. The acting end 52 has an outside diameter 58 that isapproximately the same as the tobacco plug 265 made in the compactedtobacco cavity 118. The connecting end 54 has a ball end 60 sized to fitinto a socket, which is described later. The central section 56 thatconnects the connecting end 54 to the acting end 52 is a reduceddiameter shaft that has an outside diameter 57 that is less than theoutside diameter 58 of the acting end 52. The reduced diameter of thecentral section 56 prevents the injection pin 50 from being pinched inthe compacted tobacco cavity 118 during the return stroke of the forceinput member.

The operation of the reduced diameter shaft injection pin 50 and how itprevents pinching in the compacted tobacco cavity 118 will now bedescribed. FIG. 8F shows the injection pin 50 loading a tobacco plug 265into a filling tube 450 having a blank cigarette tube 425 disposed onit. The acting end 52 of the injection pin 50 has passed beyond thecompacted tobacco cavity 118, formed in part by the correspondingcompacting plate 108, and into the filling tube 450. After the actingend 52 has passed beyond the compacted tobacco cavity 118, the forceinput member 340 typically begins its return stroke, which causes theslideable compacting plate 102 to move to its most distal position asthe force multiplying linkage returns to its fully extended position. Ifthe central section 56 of the injection pin 50 was the same diameter asthe acting end 52, as is the case for injection pin 612 shown in FIG. 1,then the injection pin would be pinched in the compacted tobacco cavity118 between the slideable compacting plate 102 and the correspondingcompacting plate 108. The reduced diameter of the central section 56 ofthe injection pin 50 prevents the injection pin from being pinched.

By the time the injection pin 50 retracts from the filling tube and theacting end 52 reaches a forward end 124 of the compacted tobacco cavity118, the force input member 340 has retracted the force multiplyinglinkage off of the center stop 350 and past its fully extended position,and is moving towards its most retracted position. As such, theslideable compacting plate 102 has moved from its most distal positionand continues to move in the direction of arrow 198, FIG. 3A, therebyallowing enough room for the acting end 52 to pass through the compactedtobacco cavity 118 without being pinched.

Another way to prevent the slideable plate 102 from pinching aninjection pin is to prevent the slideable plate 102 from moving in thedirection of arrow 197 during the return stroke by use of a split forceoutput member.

As shown in FIG. 3B, a force multiplying linkage 306 can have a secondforce output member 314 and a first force output member 363 made from afirst link 364 having a first end 366 and a second end 368 and a secondlink 370 having a first end 372, a second end 374, a first side 373, anda second side 375. The first link 364 may have a lower correspondinglink 365 and the second link 370 may have a lower corresponding link371. FIG. 3B shows the first link 364 and the second link 370 in thefully extended position. A pivotable connector 376 passing through ahole in the first end 316 of the second force output member 314 and ahole in the first end 366 of the first link 364 pivotably connects thefirst end 366 of the first link 364 to the first end 318 of the secondforce output member 314. The pivotable connector 376 also pivotablyconnects the first end 341 of the force input member 340 to the forcemultiplying linkage. Here, the pivotable connector is a bolt and a nut,but other pivotable connectors, such as pins, may also be used.

The second end 368 of the first link 364 is pivotably connected to thefirst end 372 of the second link 370 by a pivotable connector 378. Here,the pivotable connector 378 is a bolt, but another pivotable connector,such as a pin, may also be used. The second end 374 of the second link370 is pivotably connected to the first linkage connector 322 by apivotable connector 382 passing through an eye in the linkage end 323 ofthe first linkage connector 322 and through a hole in the second end 374of the second link 370. The acting end 325 of the first linkageconnector 322 is connected to the linkage support 320. Here, thepivotable connector 382 is a bolt, but another pivotable connector, suchas a pin, may also be used.

As shown in FIGS. 3B and 3D, a first stop 380 is affixed to the secondside 375 of the second link 370. Here, the first stop 380 is a stop pinthat is affixed to the second link 370 and passes through the secondlink 370. A portion 386 of the first stop 380 extends beyond a lowersurface 384 of the second link 370. A second stop pin 381 may beincluded in the lower corresponding link 371. An outer angle theta isdefined by the first link and the second link. When the first link 364and the second link 370 are in the fully extended position, a lowerportion 386 of the first stop 380 rests against the second end 368 ofthe first link 364 at a stop point 388, thereby limiting the angletheta. Typically the angle theta is limited to between 150 and 210degrees, more typically between 160 and 200 degrees, more typicallybetween 170 and 190 degrees, more typically between 175 and 185 degrees,and most typically between 178 and 183 degrees. FIG. 3B shows an angletheta that is approximately 180 degrees.

A first travel limiter 392 is positioned adjacent the center stop 350and stops the pivoting travel of the second link 370 about the pivotableconnector 382 and the first linkage connector 322. The pivoting travelis stopped when a front end 393 of the first travel limiter 392 contactsthe first side 373 at the front end 372 of the second link 370 at anapproximate location 371 while the force input member 340 is moved inthe direction of arrow 394. Typically, the first travel limiter stopsthe pivoting travel of the second link 370 about the pivotable connector382 when the pivotable connectors 376, 378, and 382 are aligned,resulting in the first end 366 of the first link 364 and the second link370 being at their fully extended position, creating an angle theta of180 degrees. But the first travel limiter may stop the pivoting of thesecond link at other positions also.

FIG. 3C shows that as the force input member continues to move in thedirection of arrow 394 after the second link 370 has been stopped by thefirst travel limiter 392, the angle theta between the first link 364 andthe second link 370 is reduced. Here, the angle theta becomes less than180 degrees. Additionally, an angle phi that was 180 degrees when thesecond force output member 314, the first link 364 and the second link370 were in there fully extended positions, becomes less than 180degrees as shown in FIG. 3C. With the angles theta and phi less than 180degrees, the first link 364, second link 370 and second force outputmember 314 are not at their fully extended positions and the slideablecompacting plate 102 has refracted from its most distal position.

When the force input member 340 retracts, the first link 364 and thesecond link 370 remain pivoted at an angle theta of less than 180degrees. And because they are free to pivot inwardly more, the angletheta may be further reduced. As such, the first force output member308, the first link 364, and the second link 370 do not return to theirfully extended position during the return stroke of the force inputmember 340. Thus, the slideable compacting plate 102 does not move toits most distal position during the return stroke of the force inputmember 340, thereby preventing it from binding an injection pin in thecompacted tobacco cavity 118.

FIG. 3E shows that during the return stroke of the force input member,the second link 370 encounters a second travel limiter 396, which limitsthe pivoting travel of the second end 374 of the second link 370 on thepivot 382. As a face 397 of the second travel limiter 396 interacts withthe second side 375 of the second link 370, the pivoting travel isstopped. As the force input member continues to retract in the directionof arrow 398, the first link 364 rotates in the direction of arrow 395until the lower portion 386 of the first stop 380 rests against thesecond end 368 of the first link 364 at a stop point 388. The forceinput member is then typically in a fully retracted position as shown inFIG. 3F.

Instead of the first force output member having a first and second linkto prevent the slideable plate 102 from moving in the direction of arrow197 during the return stroke of the force input member 340, the secondforce output member 314 may have a first and second link operating in amanner similar to the first and second link of the first force outputmember. Additionally, both the first force output member and the secondforce output member may each have a first and second link to prevent theslideable plate 102 from moving in the direction of arrow 197 during thereturn stroke of the force input member 340.

FIGS. 15A through 15F show another way that the first force outputmember 308 and the second force output member 314 may be configured toprevent the slideable plate 102 from moving in the direction of arrow197 during the return stroke of the force input member 340. A linkagesupport locking device 150 having a U-shaped pivoting locking portion154 with an end section 164 is pivotably mounted to the supporting frame302 by way of a supporting flange 152 with a pivot pin 156.

The U-shaped pivoting locking portion 154 has a first leg 160 and asecond leg 162 that straddle the first force output member 308 and alinkage support 166. The first leg 160 is adjacent to a first side 328of the force multiplying linkage and the second leg 162 is adjacent to asecond side 326 of the force multiplying linkage. The linkage support166 has an upper end 168 that is connected to the first force outputmember 308 by way of the first linkage connector 322 and a lower end 170that is hingeably connected to the supporting frame by hinge 158. Adistal end 174 of the first leg 160 has a hook 176 that locks about apin 178 mounted in the supporting frame 302 and a roller 180 that iscoplanar with the corresponding link 330 and interacts with the firstside 328 of the force multiplying linkage (see FIGS. 15A, 15B). Oneembodiment of a hook 176 is shown by portion 183 and has a pin receivingportion 182 for receiving the pin 178 and an inclined portion 184 (seeFIG. 15C). The pin receiving portion 182 may be semicircular with a knob186 for holding the pin 178. Another embodiment of the hook is shown byportion 175 in FIG. 15D. Here, the hook has an inclined portion 179, aknob or transition point 181, and a pin receiving portion 177.

Referring back to FIG. 15A, a distal end 187 of the second leg 162 has aroller 188 that is coplanar with the corresponding link 330 andinteracts with the second side 326 of the force multiplying linkage. Theend section 164 of the U-shaped pivoting locking member 154 has a roller190 that interacts with the linkage support 166.

When the force input member 340 is in a fully retracted position, thesecond side 326 of the force multiplying linkage rests against theroller 188, and the pin 178 is located in the pin receiving portion 182.The roller 190 interacts against a backside 192 of the linkage support166, preventing the linkage support 166 from moving in the direction ofarrow 194.

As the force input member 340 moves in the direction of arrow 394, thefirst force output member 308 and the second force output member 314push the slideable compacting plate 102 in the direction of arrow 197and arrive in their fully extended position where the pins 376, 334, and382 are aligned and the pin 376, the second end 312 of the first forceoutput member 308, and the first end 316 of the second force outputmember 314 are in the center position. The fully extended position ofthe first force output member 308 and the second force output member 314also correspond to the slideable compacting plate 102 being at its mostdistal position, thereby fully compacting the tobacco in the compactedtobacco cavity 118.

As the force input member 340 continues to move in the direction ofarrow 394, the pin 376, the second end 312 of the first force outputmember 308, and the first end 316 of the second force output member 314move over center towards the center stop 350. As the pin 376, second end312, and first end 316 move over center, a first side 328 of the forcemultiplying linkage 300 contacts the roller 180. Also, once the pin 376,second end 312, and first end 316 move over center, they pull theslideable compacting plate in the direction of arrow 198 away from itsmost distal position. Continued motion of the force input member 340 inthe direction of arrow 394 causes the first side 328 of the forcemultiplying linkage 300 to push against the roller 180, pivoting theU-shaped pivoting locking portion 154 about the pivot 156, anddisengaging the pin 178 from the pin receiving portion 182. As theU-shaped pivoting locking portion 154 pivots in the direction of arrow193, the roller 190 moves away from backside 192 of the linkage support166. The linkage support 166 is then free to pivot about the hinge 158and move in the direction of arrow 194.

FIG. 15F shows the U-shaped pivoting locking portion 154 pivoted aboutthe pivot 156 in the direction of arrow 194. Also shown is pin receivingportion 182 having moved away from the pin 178 and the roller 190 havingmoved away from the backside 192 of the linkage support 166, therebyallowing the linkage support to pivot in the direction of arrow 194. Agap 191 can then be observed between the linkage support 166 and thesupporting frame 302.

As the force input member 340 moves in the direction of arrow 398 on thereturn stroke, the pivoting action of the linkage support 166 in thedirection of arrow 194 allows the slideable compacting plate 102 tomaintain its current position rather than returning to its most distalposition when the first force input member 308 and the second forceinput member 314 are in their most extended positions. Thus, pivotingaction of the linkage support 166 prevents the slideable plate frompinching the injection pin.

As the force input member 340 continues retracting in the direction ofarrow 398, the second side 326 contacts the roller 188. Continued motionof the force input member 340 in the direction of arrow 398 causes thesecond side 326 of the corresponding force output member 330 to push theroller 188, and thus the distal end 187 of the second leg, in thedirection of arrow 398. The U-shaped pivoting locking portion 154 thenpivots about pivot 156 in the direction of arrow 199, causing the roller190 to push the linkage support 166 in the direction of arrow 195 as itmoves back against the backside 192 of the linkage support 166. When theforce input member 340 reaches its retracted position, the pin 178 restsin the pin receiving portion 182 and the roller 190 rests against thebackside 192 of the linkage support 166, preventing it from moving inthe direction of arrow 194 during the next forward stroke of the forceinput member.

FIG. 16A shows another type of mechanism that may be used to prevent theslideable compacting plate 102 from pinching an injection pin in thecompacted tobacco cavity 118 on the return stroke of the force inputmember 340. A spring-retained linkage support system 270 has a hingedlinkage support 272 with a linkage end 274 and a hinged end 276. Thehinged end 276 is pivotably connected to the supporting frame 302 by ahinge 292. A spring holder 268 has a rod 278 having a distal end 286with a spring retainer 280 and an opposite end that passes through ahole 282 in the hinged linkage support 272 and is affixed to thesupporting frame 302. Here, the rod is threaded into the supportingframe 302, but other methods of affixing the rod to the supportingframe, such as welding, may also be used. The spring retainer 280 biasesa spring 284 against the hinged linkage support 272.

The spring retainer 280 has a nut 288 and a washer 290. The pressure thespring exerts on the hinged linkage support 272 may be adjusted by wayof threading the nut 288 in or out on the threaded distal end 286 of therod 278.

In FIG. 16B, the force input member 340 is shown in a fully retractedposition. In the fully retracted position, the distance between areference point 344 and a front edge 349 of the slideable compactingplate 102 is shown as 346. As the force input member 340 moves in thedirection of arrow 394, the first force output member 308 and the secondforce output member 314 push the slideable compacting plate 104 in thedirection of arrow 197 and arrive in their fully extended position wherethe pins 376, 334, and 382 are aligned and the pin 376, the second end312 of the first force output member 308, and the first end 316 of thesecond force output member 314 are in the center position (see FIG.16A). The fully extended position of the first force output member 308and the second force output member 314 also correspond to the slideablecompacting plate 102 being at its most distal position with a distance336 being greater than the distance 346, thereby compacting the tobaccointo a tobacco plug. The spring 284 exerts sufficient pressure on thehinged linkage support 272 to compact the tobacco in the compactedtobacco cavity 118 before the hinged linkage support 272 pivots awayfrom the supporting frame in the direction of arrow 242.

As the force input member 340 continues to move in the direction ofarrow 394, the pin 376, the second end 312 of the first force outputmember 308, and the first end 316 of the second force output member 314move over center towards the center stop 350. As shown in FIG. 16C, oncethe pin 376, second end 312, and first end 316 move over center, theypull the slideable compacting plate in the direction of arrow 198 awayfrom its most distal position, resulting in a distance 348 being lessthan the distance 336. The pin 376, the second end 312 of the firstforce output member 308, and the first end 316 of the second forceoutput member 314 then rest against the center stop 350.

FIG. 16D shows the fully extended position of the force multiplyinglinkage when the force input member 340 is on its return stroke.Concurrently, an injection pin 612 has moved into the compacted tobaccocavity 118 to inject a tobacco plug into a filling tube (not shown). Asthe force multiplying mechanism moves to the fully extended position,the slideable compacting plate 102 moves against the injection pin 612.When the slideable compacting plate 102 hits the injection pin 612,spring 284 compresses to allow the hinged linkage support 272 to pivotaway from the supporting frame 302 on the hinge 292 so that theslideable compacting plate 102 does not bind the injection pin in thecompacted tobacco cavity. A gap 294 shows that the hinged linkagesupport 272 has pivoted away from the supporting frame 302. Typically adistance 347 is less than the distance 336 by an amount equal to a gap294 between the supporting frame 302 and the hinged linkage support 272.As the force input member 340 continues to move in the direction ofarrow 398, the slideable compacting plate 102 pulls away from theinjection pin 612 and the spring biases the hinged linkage support 272against the supporting frame 302.

FIG. 1 shows a pin mechanism 600 affixed to the base 12. As shown inFIG. 5, the pin mechanism 600 has a pin carrier support structure 602having slide receivers 605 and 606 and slides 607 and 609. Slides 607and 609 are affixed to a vertical portion 611 of the pin carrier supportstructure 602. A slideable pin carrier 604 having slide receivers 620and 622 and slides 608 and 610 is slideably mounted to the pin carriersupport structure 602 by way of slides 608 and 610 passing through slidereceivers 605 and 606 and slides 607 and 609 passing through slidereceivers 620 and 622.

Arm 626 connects a drive pin 624 to a pin 628 that is offset a distancefrom the center of a wheel 630 by arm 625. As the wheel 630 rotates, therotational motion is converted to a linear motion by arm 626, therebydriving the slideable pin carrier 604 back and forth as shown by doublearrow 632.

The slideable pin carrier 604 has a plurality of pins, including aninjection pin 612, a guide pin 614 having a guide head 615, an ejectionpin 616, and a cleaning pin 618. The slideable pin carrier may have moreor less pins, depending on the needs of the tobacco making machine.Typically, during operation, the injection pin 612 is aligned with thecompacted tobacco cavity 118.

The pins typically slide through the filling tubes, and as they do sothey may rub against the sides of the filling tubes if they are toorigid. One way to reduce friction between the pins and the filling tubesis to allow the pins to pivot on the slideable pin carrier. Oneapparatus utilizes a ball and socket joint to allow the pins to pivot.FIG. 14 shows a connector 654 having a mounting end 656 and a connectingend 658. The connecting end 658 includes a nut 666, a locknut 667, amale-threaded portion 657 for receiving the nut 666, and a firstsemicircular portion 662. The nut 666 has female threads 668 and asecond semicircular portion 664. The first semicircular portion 662 andthe second semicircular portion 664 define a socket 672 in theconnecting end. The mounting end 656 contains female threads 659 forreceiving a bolt 674 which affixes the connector 654 to the slideablepin carrier 604. Other methods of affixing the mounting end 656 of theconnector 654 to the pin carrier may also be used.

FIG. 14 shows a representative pin 650 having an acting end 655 and aconnecting end 652. Depending on the configuration of the acting end ofthe pin, the pin may be a guide pin 614, an injection pin 612, acleaning pin 618, an ejection pin 610, or any other type of pin. Here,the connecting end is a ball sized to fit in the socket 672. The balland socket design allows the pin two degrees of freedom, as representedby the y and z axis of 676. Alternatively, other means of connecting theconnecting end of the pin to the slideable pin carrier may also be usedto provide two degrees of freedom to the pin. For example, instead ofthe connecting end of the pin 650 having the ball and the connecting endof the connector having a socket, the connecting end 652 of the pin mayhave a socket and the connecting end of the connector may have a ball.Also, other methods of connecting a pin to the pin carrier, such as aspring, may also be used to provide two or more degrees of freedom tothe pin.

FIG. 6A illustrates a filling tube 450 having a first end 451, a secondend 452, an inside diameter 453, and an outside diameter 454. Othershapes of tubes may be used as filling tubes, including square oroctagonal shaped tubes. The first end 451 of the filling tube may have ashoulder 455 for securing the filling tube 450 to a filling tube holder(not shown). Alternatively, a filling tube may be secured to a fillingtube holder (not shown) by other means, such as press fit, welded, orthreaded connections. FIG. 6B shows an embodiment of the filling tube459 without a shoulder that may be press fit or welded to a filling tubeholder (not shown). The first end 451, may have a taper 458 from thefirst end 451 outside diameter 456 to the inside diameter 453 forreceiving a guide head 470.

FIG. 7A illustrates an embodiment of a guide head 470. The guide head470 has a distal end 471 and a proximal end 472 and is sized to fitwithin the inside diameter 453 of the filling tube 450. The proximal end472 of the guide head 470 has fastening means 473 for attaching theguide head 470 to a pin 474 having a complimentary fastening means 475.The fastening means 474 and 475 can be a threaded connection, a pressfit, or other methods known to those of ordinary skill in the art.Additionally, the guide head 470 and the pin 474 may be fabricated froma single piece of material. The distal end 471 of the guide head 470 hasa substantially conical head 476. A largest diameter 477 of the conicalhead 476 is typically equal to or greater than the outer diameter 454 ofthe filling tube 450. Therefore, the conical head 476 is collapsible toenable it to pass through the filling tube 450 and exit out the secondend 452 of the filling tube 450.

Various means may be used to provide a collapsible guide head. In theembodiment 470 shown in FIG. 7A, a plurality longitudinal slots 465 arecut from a tip 478 of the conical head 476 to a slot terminationlocation 467. The slots typically terminate at a radius 466 to reducestresses that the slots may induce into the guide head material andthereby prevent self propagation of the slots toward the proximal end472 of the guide head 470. The guide head 470 may be made from a varietyof materials, including plastics and metals. Typically, one may use ahardened steel, such as 01 steel hardened to 58-60 Rockwell C, for theguide head. Other means, such as a flexible rubber guide head, a polymerguide head, or an inflatable guide head may be used to produce acollapsible guide head.

FIG. 7B illustrates an embodiment of a pin 462 with guide head 463 inwhich the outside diameters of the pin 462 and the guide head 463 areequal to or less then the inside diameter 453 of the filling tube 450.In this embodiment, the guide head 463 does not need to collapse to passthrough the filling tube 450.

FIG. 8A shows a filling tube holder 400 comprising a drum 401 having afirst end 402 and a second end 403. The first end 402 of the drum 401has a plurality of holes 404 and 405 for receiving a plurality offilling tubes 450. Other holes (not shown) for receiving filling tubesmay also be disposed on the first end 402 of the drum 401.

This description describes filling tube 450 and the features in the drum401 associated with filling tube 450. Other filling tubes mounted in thedrum will typically be mounted in a similar manner, and the drumtypically will have similar features for each of the other fillingtubes. One method of attaching a filling tube 450 to a drum 401 is aclamping device 408 for clamping against the shoulder 455 on the firstend 451 of the filling tube 450. Alternatively, other means forattaching the filling tubes to a filling tube holder may be used. Forexample, the filling tubes and the plurality of holes in the holder forreceiving the filling tubes may be threaded. Also, the filling tubes maybe threaded to receive a nut after passing through a hole in the drum.Additionally, other methods instead of a drum may be used for holding aplurality of tubes, for instance, the filling tubes may be mounted on aplate or on a belt.

Axially aligned with the filling tube hole 404 is a conical directinghole 411 having a proximal end 412 and a distal end 413. The distal end413 of the cone shaped hole defines the larger diameter of the cone, andthe diameter of the proximal end of the cone shaped hole is slightlylarger than the outside diameter of a blank cigarette tube (discussedlater).

FIG. 8B is a partial section view of the drum 401 having the fillingtube 450 into which the guide head 470, typically attached to a pin (notshown), is passing. As the conical head 476 of the guide head 470 passesinto the first end 451 of the filling tube 450, the filling tube 450squeezes the guide head 470, thereby collapsing guide head 470 andallowing the largest diameter 477 of the guide head 470 to be less thanthe inside diameter 453 of the filling tube 450.

FIG. 8C is a partial section view of the drum 401 having the fillingtube 450 through which the conical head 476 of the guide head 470,typically attached to a pin (not shown), has passed. The conical head476, having passed through the second end 452 of the filling tube 450,can be observed in its relaxed state with the large diameter 477 of theguide head 470 now equal to or greater than the outside diameter 454 ofthe filling tube 450.

FIG. 8D illustrates a blank cigarette tube 425 being loaded onto thefilling tube 450. The conical head 476 extends beyond the filling tube450. The blank cigarette tube loader 700 (described later) induces aforce on a filter end 426 of a blank cigarette tube 425, causing theblank cigarette tube 425 to move toward the conical head 476 of theguide head 470. In this illustration, an open end 427 of the blankcigarette tube 425 has been damaged, resulting in the normal circularshape of the end of the blank cigarette tube 425 becoming oblong. As theblank cigarette tube 425 moves toward the guide head 470, the proximalend 412 of the conical hole 411 in the drum 401 will operate to returnthe oblonged open end 427 of the blank cigarette tube 425 to a morecircular shape. The blank cigarette tube 425 continues through theconical hole 411, over the conical head 476, and then onto the fillingtube 450.

FIG. 8E is similar to FIG. 8D, with the exception that the blankcigarette tube 425 has been fully inserted on the filling tube 450.Thereafter, the guide head 470 is removed from the filling tube 450 bywithdrawing it out through the first end 451 of the filling tube 450.The filling tube 450 and blank cigarette tube 425 are then ready toreceive the tobacco plug 265 prepared by the previously discussedtobacco compaction mechanism 100.

FIG. 8G illustrates an ejection pin 616 ejecting a completed cigarettetube 430, having been filled with a tobacco plug 265, from the fillingtube 450.

As shown in FIG. 12, the drum is driven and timed with a Geneva drive.Other types of driving and timing mechanisms may also be used. TheGeneva drive translates the continuous rotary motion of a drum driveshaft 750 into intermittent rotary motion. The drum has a plurality ofdrum plates 752 with semicircular cutouts 754 and a slot 756 betweeneach plate. A drive wheel 758 has a roller 760 with a diametercorresponding to the width of the slots 756 and a semicircular plate 762with dimensions corresponding to the semicircular cutouts of the drumplates. As the drive wheel rotates, the roller 760 enters slot 756,thereby rotating the drum forward. As the drive wheel continues torotate, the roller exits the slot, and a leading edge 761 of thesemicircular plate 762 engages in the semicircular cutout 754, holdingthe drum in position until the pin engages the next slot and the processis repeated.

Referring now to FIG. 9, in operation, a motor 502 drives a gear reducer504. An output shaft 506 from the gear reducer 504 has a first beveledgear 508 and a force input member wheel 510 mounted to it. As shown inFIG. 13B, the wheel 510 has a center 513 and a force input member arm515 having a pin 511 that is offset a distance from the center of thewheel. The second end 343 of the force input member 340 is pivotableconnected to the arm 515 by pin 511. The force input member 340 has adwell mechanism that allows the force multiplying linkage to be at anover center position against the center stop 350 for a predeterminedperiod of time during continued rotation of the wheel 510. One method ofincorporating dwell is using a spring loaded force input member 340.

FIG. 13A shows a force input member 340 that is collapsible to allow adwell time for the force multiplying linkage. The force input member 340includes a first portion 552 with a receiving section 554 that slideablyreceives a second portion 556. A spring 558 is disposed between a firstretainer 560 that is attached to the first portion 552 and a secondretainer 562 that is attached to the second portion 556. The secondportion 556 has a slot 564 having a first end 566 and a second end 568sized to receive a pin 570 that is attached to the first portion 552.The force input member 340 shown in FIG. 13A is in the collapsedposition, as indicated by the pin 570 resting against the first end 566of the slot 564. When the force input member 340 is in the extendedposition, the pin 570 will rest against the second end 568 of the slot564.

FIG. 13B shows the second end 343 of the force input member 340connected to a pin 511 of the wheel 510 and the first end 341 of theforce input arm 340 connected to the force multiplying linkage 300. Asthe wheel 510 rotates in the direction of arrow 576, the force input arm340 is typically in the extended position until the pin 511 reaches alocation 572. When the pin reaches the location 572, the forcemultiplying linkage hits the center stop 350, which prevents furthertravel of the force multiplying linkage in the direction of arrow 394.As the wheel 510 continues to rotate, the spring 558 is compressed. Theforce input arm 340 is in a compressed position, as shown in FIG. 13A,when the pin reaches a location 573. The spring remains compressed untilthe pin 511 of the wheel 510 reaches a location 574, by which time theforce input member 340 has returned to its extended position. Thecollapsible force input member 340 allows the force multiplying linkageto remain, or dwell, in its position against the center stop 350 as thepin 511 moves from location 572 to location 574.

Referring to FIGS. 9 through 11, the first beveled gear 508 drives asecond beveled gear 512 that is attached to a shaft 514. The shaft 514passes through shaft support 516 and has a third beveled gear 518affixed to it opposite the second beveled gear 512. The third beveledgear 518 mates with a fourth beveled gear 520 that is mounted on a shaft522. The shaft 522 passes through shaft support 526 and has a fifthbeveled gear 524 affixed to it.

A sixth beveled gear 527 (not shown) meshes with the fifth beveled gear524 and is affixed to one end of a shaft 528. A seventh beveled gear 529is affixed to the shaft 528 opposite the beveled gear 527. An eighthbeveled gear 530 meshes with the seventh beveled gear 529 and is affixedto a shaft 531 that passes through the pin carrier support 602 and has awheel 630 with an arm 625 affixed to it opposite the sixth beveled gear530. The arm 625 is connected to the slideable pin carrier 604 by an arm626. The shaft 750 that drives the drive plate 758 of the Geneva drivemechanism has a beveled gear (not shown) also interacting with the sixthbeveled gear 527.

Typically, one rotation of the output shaft 506 will result in onecigarette being made. Because, the output shaft typically rotates a fullrevolution without stopping and some mechanisms require dwell time incertain positions, various timing and dwell mechanisms may be used.

The cigarette making machine may also be manually driven by turning ahand wheel 550. A shaft 578 passes through support 580 and connects thehand wheel 550 to a beveled gear 582. Instead of using the motor 502 todrive the cigarette making machine, an operator may use the hand wheel550 to drive the beveled gear 582, which in turn operates the cigarettemaking machine.

Other methods may also be used to drive the cigarette making machine.For example, instead of the multiple beveled gears, one motor may beused to drive the wheel 510 that operates the force input member 340 todrive the force multiplying linkage 300, one motor may be used to drivethe wheel 630 that drives the slideable pin carrier, and one motor maybe used to drive the driven wheel of the Geneva gear, which drives thedrum 401. When multiple motors are used instead of a single motor withbeveled gears to drive and time the various operations, a timingmechanism is used to synchronize the motors. The timing mechanism may becomponents on a PCB, a PLC, or other various sensors or timers. Also,linear actuators may be used in place of at least some of the motors.For example, a linear actuator may be used in place of the wheel 510 andthe force input member 340 to drive the force multiplying linkage and alinear actuator may be used in place of the wheel 630 and arm 626 todrive the slideable pin carrier. When linear actuators are used, atiming mechanism such as timers, components on a PCB, a PLC, or othervarious sensors or timers may be used to synchronize the linearactuators.

FIG. 12 shows the cigarette making machine having a blank cigarette tubeloader 700. The blank cigarette tube loader 700 has a slideable body 702comprising a body 704 with a handle 706 and a pusher 708. A blankcigarette tube loader base 710 carries a guide 712 on which the body 704slides. A spring 714 operates against a stop 716 affixed to the blankcigarette tube loader base 710. A trough 726 is sized to receive a blankcigarette tube 425.

To operate the blank cigarette tube loader, a user places a blankcigarette tube 425 into the trough 726. Then, by pushing the handle 706in the direction of arrow 728, the pusher 708 pushes the blank cigarettetube 425 onto the filling tube 450. The spring 714 assists the user inreturning the handle 706 to the start position after loading a blankcigarette tube onto a filling tube.

An arm 718 having a cigarette stop 720 may also be affixed to the blankcigarette tube loader base 710. The cigarette stop prevents a blankcigarette tube 425 from being pushed off of the filling tube 450 when itis being loaded with a tobacco plug by the injection pin 612. The stop720 may also be adjustable. For example, the stop 720 has a bolt 722secured with a lock-nut 724 and passing through a threaded hole in thearm 718. The cigarette stop may be mounted to structures other than thearm 718 and still perform the same function.

To operate the cigarette making machine, a user pushes a button to causethe motor 502 to drive the slideable pin carrier 604 in the direction ofarrow 619 (see FIG. 1) to a forward position shown so that the guidehead 615, which guides the blank cigarette tube 425 onto the fillingtube 450, of the guide pin 614 passes through the filling tube 450 asshown in FIGS. 8C and 8D. The user then inserts a blank cigarette tube425 located at a station 414 (see FIG. 12) over a filling tube 450mounted to a drum using the blank cigarette tube loader 700.Alternatively, the user could insert the blank cigarette tube 425 overthe filling tube 450 manually without using the blank cigarette tubeloader.

The user then presses a start button to begin a cigarette making cycle.First, slideable pin carrier 604 retracts in the direction of arrow 621(see FIG. 1) and the tobacco conveying device 200 conveys apredetermined amount of tobacco to the compaction area 114. The rotatingoutput shaft 506 drives the wheel 510, causing the force input member340 to drive the force multiplying mechanism 300. The force multiplyingmechanism 300 slides the slideable compacting plate 102 in the directionof 197, causing the compacting end 104 to compact the tobacco in thecompaction area 114 into a compacted tobacco plug 265 in the compactedtobacco cavity 118.

While the tobacco compaction mechanism 100 is compacting the tobacco,the Geneva drive mechanism rotates the drum 401 to move the filling tubewith the previously loaded blank cigarette tube to station 416 where itis axially aligned with the compacted tobacco plug 265 located in thecompacted tobacco cavity 118 (see FIG. 12).

Referring also to FIG. 1, the slideable pin carrier 604 then movesforward in the direction of arrow 619, causing the injection pin 612,which is axially aligned with the compacted tobacco cavity 118, toinject the tobacco plug 265 into the filling tube 450. Because theinjection pin 612 and the guide pin 614 with the guide head 615 are bothattached to the slideable pin carrier 604, the guide head passes throughthe filling tube located at station 414 at the same time the injectionpin 612 injects the tobacco plug 265. The motor then pauses to allow theuser to load another blank cigarette tube onto the adjacent fillingtube.

The user again pushes the start button after loading a blank cigarettetube onto the filling tube located at station 414. The cycle ofretracting the slideable pin carrier 604, conveying and compacting thetobacco, and injecting the tobacco then begins again. During this cycle,filling tube having the first loaded tube moves to location 418.

The machine pauses again to allow a user to load another blank cigarettetube onto a filling tube at location 414. Pressing the start button,another cycle is run. During this cycle, the first loaded tube moves tostation 420 and a completed cigarette is ejected by the ejection pin 616when the slideable pin carrier 604 moves in the direction of arrow 619.Alternatively, another cycle could be completed and the cigarette couldbe ejected at station 422.

During each cycle, the cleaning pin 617 is pushed through and cleans thefilling tube located at station 424 when the slideable pin carrier 604moves in the direction of arrow 619. Thus, the filling tube is cleanedbefore it moves forward to station 414, where it is loaded with a blankcigarette tube. While a typical blank cigarette tube is made from a woodbased paper, the blank cigarette tube may be made from reconstitutedtobacco leaf sheet.

A cigarette blank 10 made with reconstituted leaf sheet is shown in FIG.18. The cigarette blank 10 has a filter end 12 having a filter 14 and afillable end 16. At least the fillable end is made from reconstitutedleaf sheet 18 and is hollow for receiving tobacco or other smokablematerial. Tipping paper 13 surrounds the reconstituted tobacco paper atthe filter end 12. The tipping paper protects the reconstituted leafsheet from degradation from saliva while a user is smoking a cigaretteand is typically designed not to stick to a smoker's lips. FIG. 19 showsan end view of the filter end of the cigarette blank 10 of FIG. 18showing the filter 14, reconstituted leaf sheet 18, and tipping paper13.

Traditional cigarette tubes are made from thin-tissue like paper basedon wood products. With reconstituted leaf sheet, the user is provided amore tobacco like smoke product because the user is not burning woodwhen smoking the cigarette.

The reconstituted leaf sheet is typically made from tobacco fines,tobacco stems, and tobacco particles that are collected at any stage oftobacco processing that are processed and formed into a sheet product.The reconstituted leaf sheet typically contains between about 50% and99% tobacco, more typically between about 60% and 80% tobacco, moretypically between about 65% and 75% tobacco, and most typically about67% tobacco with the balance being binders and fillers. While notlimiting the scope or properties of reconstituted leaf sheet, oneexample of reconstituted leaf sheet has the following properties:

Property Units Minimum Target Maximum Bone Dry Basis g/m² 42.6 43.3 44.0Weight Porosity CORESTA 10.0 25.0 40.0 MD Tensile g/in 1,600 2,050Moisture % 9.3 10.5 11.7 Filler % 15.0 18.0 21.0 Tobacco Content % 67.0

Typically, one specification for cigarette tubes manufactured fromreconstituted leaf sheet are as follows:

Feature Specification Tolerance (+/−) Tube Diameter 8.1 mm 0.5 mm TubeCircumference 25.44 mm 0.25 mm Tube Length 84 mm 1.0 mm Tube Weight 300mg 10 mg Filter Length 20 mm 1.0 mm Filter Pdrop @120 mm 1 g 300 mm/H₂O15 mm/H₂O Filter Weight 895 mg 10 mg Filter Tow (Denier) 3.4  0.3 g/9000m Total Denier per filament 31,000  1800 g/9000 m Filter VentilationNone Filter Density 126 mg/cc 10 mg/cc Filter PZ 60 mg/100 m 2% TobaccoWrapper Size 28 mm × 84 mm 1.0 mm Long Tobacco Wrapper CU 25 CU 15 CUTobacco Wrapper weight 43.3 g/m² 0.7 g/m² Tipping Paper Size 28 mm × 24mm 1.0 mm Tipping Paper Permeability 0 CU 0 CU

A typical king sized cigarette, described above, is 84 mm long. Otherlarger and smaller cigarettes may also be make using reconstituted leafsheet, including a 100 mm tube, which typically has an overall length of100 mm and is made with a filter 25 mm long×8.1 mm diameter tippingpaper 30 mm long×28 mm diameter, and reconstituted leaf sheet 100 mmlong×28 mm diameter.

The reconstituted leaf sheet cigarette blanks are typically made on acigarette tube machine. One example of such a machine is described inU.S. Pat. No. 3,693,313. Typical materials used to make a cigarette tubeof reconstituted leaf sheet are reconstituted leaf sheet, tipping paper,and a filter.

FIG. 20 shows a method of making a tobacco blank with reconstituted leafsheet. Reconstituted leaf sheet 30 is fed from a roll into a cigaretteblank making machine. A filter 32, which is twice the length of a filtertypically found on a cigarette, is glued to the reconstituted leaf sheetat a filter location 36 on the reconstituted leaf sheet. The distancebetween the filter locations 36 is typically twice the length Glue isapplied to the inside upper edge 34 of the reconstituted leaf sheet. Theinside upper edge 34 is folded over an opposite edge 38 and glued to theopposite edge 38. Tipping paper 44 is glued around the paper holding thefilter 32 at the filter location 36.

As shown in FIG. 21, a tube 42 containing filters 32 continues to acutting operation shown in FIG. 22. In the cutting operation, the tubeis severed between the filters and the filters are severed in half toproduce cigarette blanks 46.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not intended to restrict or in any way limitthe scope of the appended claims to such detail. Additional advantagesand modifications will be readily apparent to those skilled in the art.The invention is therefore not limited to the specific details,representative apparatus and method, and illustrated examples shown anddescribed. Accordingly, departures may be made from such details withoutdeparting from the scope or spirit of the invention.

What is claimed is:
 1. A cigarette blank comprising a. a tube having afirst end and a second end, wherein the tube is made of reconstitutedleaf sheet, and b. a filter disposed in the second end of the tube. 2.The cigarette blank according to claim 1, wherein the reconstituted leafsheet contains at least 50% tobacco by weight.
 3. The cigarette blankaccording to claim 1, wherein the reconstituted leaf sheet containsbetween 60% and 80% tobacco by weight.
 4. The cigarette blank accordingto claim 1, wherein the reconstituted leaf sheet contains between 65%and 75% tobacco by weight.
 5. A method of making a cigarette comprisinga. providing a cigarette blank having a tube with a first end and asecond end, a filter disposed in the second end of the tube, wherein thetube is made of reconstituted leaf sheet, b. providing a filling tubehaving a first end, a second end, an inside diameter, and an outsidediameter, c. providing a pin sized to fit within said filling tube, saidpin having a first end and a second end, said second end comprising aguide head, d. inserting said pin into said filling tube so at least aportion of the guide head of said pin extends beyond the second end ofsaid filling tube, e. dispensing the cigarette blank over said guidehead and onto said filling tube, and f. retracting said pin from saidfilling tube.
 6. The method according to claim 5, further comprisingejecting a cylinder of tobacco into the filling tube.
 7. The methodaccording to claim 6, further comprising ejecting a completed cigarettefrom said filling tube.
 8. A method of making a cigarette comprising thesteps of delivering an amount of tobacco to a tobacco compaction area,compacting the tobacco, inserting a cigarette blank made ofreconstituted leaf sheet over a filling tube, and injecting a plug ofcompacted tobacco into a filling tube with an injection pin affixed to aslideable pin carrier.
 9. The method of making a cigarette according toclaim 8, wherein the compacting step further comprises moving the forcemultiplying linkage to an over center position and maintaining thatposition for a predetermined period of time.
 10. The method of making acigarette according to claim 8 wherein the inserting step comprisesguiding the blank cigarette tube onto a filling tube with a guide head.